System and method for forming laminated materials for mattresses

Abstract

A laminating system and method for forming laminated bedding materials such as for mattress borders or other bedding components. The laminating system includes a frame on which a series of supply rolls of different bedding material are supported. An adhesive is applied between the bedding material layers, after which the bedding material layers are fed into registration with each other. The side edges of the bedding material layers can then be serged to seal their side edges, and the bedding material layers passed through compression rollers to press and laminate the bedding material layers together in tight adhesive contact.

1 . A system for laminating mattress components comprising:
 a frame;   a supply of a first bedding material mounted on the frame and fed along a path of travel;   a supply of a second bedding material mounted on the frame and fed toward a point where the second bedding material is brought into registration and engagement with the first bedding material being fed along its path of travel;   at least one adhesive applicator upstream from the point where the second bedding material is brought into registration and engagement with the first bedding material for applying an adhesive material between the first and second bedding materials prior to the first and second bedding materials being brought into registration; and   a series of rollers located downstream from the point where the second bedding material is brought into registration and engagement with the first bedding material, wherein the first and second bedding materials are passed between the rollers and compressed so as to bond the bedding materials together in a laminated structure.   
     
     
         2 . The system of  claim 1  and further comprising at least a first sewing station for serging at least one side edge of the first and second bedding materials together after the first and second bedding materials have been brought into registration. 
     
     
         3 . The system of  claim 2  and further comprising a second sewing station arranged adjacent the first sewing station on an opposite side of the path of travel of the first and second bedding materials for serging another side edge of the first and second bedding materials. 
     
     
         4 . The system of  claim 2  and further comprising a second sewing station arranged along a reverse side of the path of travel of the first and second bedding materials for serging another side edge of the bedding materials. 
     
     
         5 . A method of forming laminated bedding materials, comprising:
 moving a first bedding material layer along a path of travel;   moving a second bedding material layer along a path of travel and toward registration with the first bedding material layer;   applying an adhesive material to at least one of the first and second bedding material layers prior to the first and second bedding material layers moving in t o registration; and   pressing the bedding material layers together to bond the bedding material layers into a laminated structure.   
     
     
         6 . The method of  claim 5 , further comprising attaching at least one side edge of the bedding material layers together after the bedding material layers have been brought into registration. 
     
     
         7 . The method of  claim 5 , wherein the bedding materials are brought into registration and are laminated together along a single, converging path of travel. 
     
     
         8 . The method of  claim 7 , further comprising engaging and sewing opposite side edges of the bedding material layers to attach the bedding material layers together along their side edges prior to pressing the bedding material layers together. 
     
     
         9 . The method of  claim 8 , wherein engaging and sewing opposite side edges of the bedding material layers comprises moving the opposite side edges of the bedding material layers through sewing heads arranged along opposite sides of the converging path of travel of the bedding material layers. 
     
     
         10 . The method of  claim 8 , wherein engaging and sewing opposite side edges comprises sewing a first side edge of the bedding material layers along a first portion of their converging path of travel, inverting the bedding material layers and sewing a second side edge of the bedding material layers. 
     
     
         11 . The method of  claim 5 , wherein applying an adhesive material comprises moving at least one adhesive applicator head transversely with respect to at least one of the path of travel of the first bedding layer or the path of travel of the second bedding layer to apply the adhesive material between the first and second bedding layers. 
     
     
         12 . The method of  claim 11 , wherein the at least one adhesive applicator head applies the adhesive material by spraying or extruding the adhesive material between the first and second bedding material layers. 
     
     
         13 . The method of  claim 5 , wherein applying an adhesive material comprises moving an adhesive applicator head transversely across the path of travel of the first bedding material layer and across the path of travel of the second bedding material layer for applying the adhesive material to a surface of each of the first and second bedding material layers. 
     
     
         14 . A system for forming laminated fabric materials, comprising:
 a series of material rolls each feeding a material layer toward registration along a path of travel;   at least one adhesive applicator located along the path of travel of the material layers fed from the supply rolls for applying an adhesive material between at least selected ones of the material layers; and   a sewing zone downstream from a point at which the material layers are fed into registration, with at least one sewing machine located along the sewing zone for engaging and attaching side edges of the material layers.   
     
     
         15 . The system of  claim 14 , wherein the sewing zone comprises a second sewing station arranged adjacent the first sewing station on an opposite side of the path of travel of the first and second bedding materials for serging another side edge of the first and second bedding materials. 
     
     
         16 . The system of  claim 14 , further comprising a second sewing station arranged along a reverse side of the path of travel of the first and second bedding materials for serging another side edge of the bedding materials. 
     
     
         17 . The system of  claim 14 , further comprising a laminating station downstream from the sewing zone, for engaging and pressing the material layers into a laminated material. 
     
     
         18 . The system of  claim 14 , wherein the at least one adhesive applicator comprises a movable adhesive head that is movable between the at least two material layers and in a direction transverse to the path of travel of the material layers and which applies an adhesive material in a desired pattern to at least one of the material layers. 
     
     
         19 . The system of  claim 14 , wherein the series of material rolls comprises a roll of backing material, a roll of filler, and a roll of ticking material. 
     
     
         20 . The system of  claim 19 , wherein the at least one adhesive applicator comprises a series of adhesive heads each movable between two of the material layers and in a direction transverse to the path of travel of the material layers for applying an adhesive material in a desired pattern to at least one of the material layers. 
     
     
         21 . The system of  claim 14 , further comprising a roll of flanging material. 
     
     
         22 . The system of  claim 14 , further comprising material run-out detectors on at least selected ones of the material rolls.